Controls Lab

Lab Report Number: 07

“ON-OFF Control of flow and effect of

Section: ME-14 (C)

Name CMS ID
Muhammad Ahmad Nadeem 416175
Table of Contents
Objectives ............................................................................................................... 2
Equipment............................................................................................................... 2
Theoretical Background............................................................................................ 2
Procedure ............................................................................................................... 3
Circuit Representation ............................................................................................. 4
Data Tabulation ....................................................................................................... 4
Graphical Representation ......................................................................................... 5
Discussion .............................................................................................................. 5
Conclusion ................................................................... Error! Bookmark not defined.
Safety Precautions ................................................................................................... 6

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Objectives:
• To understand the basic principles of ON-OFF control in flow control systems.
• To investigate the performance of an ON-OFF control system in regulating fluid
flow.
• To study the effect of hysteresis on the stability and efficiency of flow control.
• To explore the causes of hysteresis in flow control systems and identify
methods to mitigate its effects.
• To assess ON-OFF control's practical applications and limitations in industrial
flow systems.

Equipment:

Figure 1: Apparatus

Theoretical Background
ON-OFF Control of Flow:

ON-OFF control is a simple method used to regulate fluid flow, operating in two states:
ON (full flow) and OFF (no flow). The controller activates when the flow rate deviates from
the setpoint, with a hysteresis band to prevent constant switching, providing stability in
less critical applications.

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Effect of Hysteresis on Flow Control Systems:

Hysteresis prevents the system from rapidly switching between ON and OFF states by
creating a range where the system does not react to minor fluctuations. It helps reduce
mechanical wear and energy consumption but can lead to slight inaccuracies in the flow
rate, as the system only responds when flow surpasses certain thresholds.

Impact on System Performance:

Hysteresis reduces switching frequency, improving stability and saving energy. However,
it introduces inaccuracy as the flow may not immediately adjust within the hysteresis
band. This is a trade-off between energy efficiency and flow precision.

ON-OFF control with hysteresis is an effective, cost-efficient method for less sensitive
applications but may cause slight variations in flow where high precision is needed. It
provides a balance between stability and simplicity in many industrial settings.

Procedure:
• The apparatus was set up, and all necessary connections for the flow control
system were established.
• The ON-OFF control system was powered on, and the flow meter was activated.
• The desired setpoint for flow rate was input into the controller, and the actual flow
rate was recorded.
• The system was observed without the inclusion of hysteresis.
• The same setpoints were tested again, and the corresponding flow rates were
recorded with hysteresis applied.
• The flow rate readings were documented, both with and without hysteresis.
• The control system was powered off, and the experiment was concluded.

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Circuit Representation

Figure 2: Circuit

Data Tabulation
Table 1: Data Table

Hysteresis No Hysteresis (0%) With Hysteresis (25%)

Setpoint 4 LPM 4 LPM

Rising Time 0.28sec 0.56sec

Upper limit 4.2 LPM 4.8 LPM

Lowering time 0.39 sec 0.505 sec

Lower limit 3.8 LPM 3.2 LPM

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Graphical Representation:
5
4.5
4
3.5
3
level(cm)

2.5
2
1.5
1
0.5
0
0 1 2 3 4 5 6 7
time(s)

Figure 3: Graph with 0% hysteresis

Figure 4: Graph with 25% hysteresis

Discussion:
In this lab, we studied the effect of hysteresis on the behavior of the Flow Control Training
System. The ON-OFF control system, with and without hysteresis, demonstrated distinct
behaviors in maintaining flow rates. Without hysteresis, the system experienced frequent
ON/OFF transitions, causing significant instability and oscillations around the setpoint.
Introducing hysteresis reduced the switching frequency, which led to steadier flow
control and minimized rapid fluctuations. However, this improvement came with a slight
compromise in precision, especially near the setpoint. The graphs clearly illustrate this

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trade-off: while the system became more stable with hysteresis, small deviations in the
flow rate were observed.

This balance between stability and accuracy underscores the importance of hysteresis
in optimizing control systems. By increasing hysteresis, the system efficiency improves
by reducing excessive switching, but precise flow control is slightly diminished. This
trade-off is often necessary for practical applications where system longevity and
efficiency are prioritized over perfect accuracy.

Conclusion:
ON-OFF control with hysteresis offers a reliable approach to flow regulation by reducing
switching frequency and enhancing system stability. The resulting minor reduction in flow
accuracy is an acceptable trade-off in many non-critical applications. By carefully
adjusting hysteresis levels, it is possible to achieve a balance between stability,
efficiency, and accuracy, making the system adaptable for various real-world scenarios
where minor deviations can be tolerated.

Safety Precautions:
• Personal Protective Equipment (PPE): Ensure that all lab personnel wear
appropriate PPE, including safety goggles, lab coats, gloves, and closed-toe shoes
to protect against chemical splashes, electrical hazards, or mechanical injuries.
• Equipment Inspection: Regularly inspect all lab equipment and apparatus for any
signs of damage or wear. Report any defects immediately and ensure that faulty
equipment is taken out of service until repaired or replaced.
• Emergency Procedures: Familiarize all lab members with emergency procedures,
including the location of fire extinguishers, eyewash stations, safety showers, and
emergency exits. Conduct regular safety drills.
• Hazardous Materials Handling: Follow proper procedures for handling, storing,
and disposing of hazardous materials, such as chemicals and solvents. Use fume
hoods and ventilation systems as needed.
• Electrical Safety: When working with electrical circuits and equipment, ensure
that power sources are disconnected before making connections or adjustments.
Avoid contact with exposed wires and use insulated tools.
• First Aid Kit: Maintain a well-equipped kit in the lab and ensure lab personnel are
trained in basic first aid procedures. Display emergency contact numbers and
locations prominently.